1. Intuitive Operator Support by new Process Visualization
Dirk Stevens, Power Generation; Dr. Martin Hollender, Moncef Chioua, Corporate Research Center
Intuitive Operator Support by new Process Visualization
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2. Agenda Current Status System 800xA Optimized Displays
System 800xA Alarm Management
Summary
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3. „I would have liked to have thrown away the alarm panel
„I would have liked to have thrown away the alarm panel. It wasn't giving us any useful information.”
Craig Faust, operator of the Three Mile Island Nuclear Power Plant during the official analysis of the TMI accident
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4. Typical number of alarms
Petro-
chemistry
Power production
* Soucre: Engineering Equipment and Materials User’s Association
EEMUA*
Oil & Gas
others
Alarms per day
(Average)
144
1200
1500
2000
900
Persisting alarms
(Average) 9 50
100 65 35
Peak value per 10 min. 10
220
180
350
180
Average/ 10 min. Interval 1 6 9 8 5
Distribution % (low/middle/high)
80/15/5
25/40/35
25/40/35
25/40/35
25/40/35
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5. Results of an ABB field study in control centers
Often the symptoms were analyzed, without looking for the real cause
Troubleshooting often by try and error
Most important method for troubleshooting:
„Is somebody familiar with this problem?“
Operators must remain in the loop for all current tasks
Complex long lasting tasks (for more than one shifts) are not supported by many systems
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6. Challenges in the operation of power plants
Maximization of availability and performance
High demands on efficiency and environmental protection
More flexible operation modes, to balance the variations caused by the renewable power production
Scope of the used fuel
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7. Challenges in the operation of power plants
Modern power plants are highly automated but nevertheless
the operator must have the possibility to build up and to extent his competence in order to
control unforeseen situations
detect and resolve upcoming problems as early as possible
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8. System 800xA Optimized Displays and Alarm Management
Optimized spatial fixed and always visible large-screen displays
Counteract the “keyhole effect”
Usage of pattern recognition abilities of the operators
Common basis for team discussions
(Early –) detection – understanding - action
Optimization of the alarm system
The operators are able to use the alarm system more efficiently
Important alarms do not disappear in an alarm flood
The operators are supported by an alarm database
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9. Mass data displays Features
Systematic approach provides a good overview
Spatial fixed and always visible overview
Usage of high-capacity pattern recognition abilities of the operators
Challenge
Efficient calibration (Which values are equivalent to the angles 90°,0°,-90°)
Under normal conditions a regular and smooth pattern should be displayed
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10. Calibration of mass data displays5 4 3
frequency
value
Calibration
Mainly automated on the basis of historical values
Definition of multiple typical steady modes
Recording of histograms for each mode
Generation of parameters
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11. Histogram for various process modes
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12. Software Architecture
System 800xA
Process history
Steady State
Fingerprint Editor
Detection of process failures
Selected values
Calibration
parameter
State detection
Process value
normalization
Selection and grouping
Definition of process modes
Selection of time intervals
fine tuning
Quality control
Visualization
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13. Typical number of alarms
Petro-
chemistry
Power production
* Soucre: Engineering Equipment and Materials User’s Association
EEMUA*
Oil & Gas
others
Alarms per day
(Average)
144
1200
1500
2000
900
persisting alarms
(Average) 9 50
100 65 35
Peak value per 10 min. 10
220
180
350
180
Average/ 10 min. Interval 1 6 9 8 5
Distribution % (low/middle/high)
80/15/5
25/40/35
25/40/35
25/40/35
25/40/35
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14. Alarm Management according to EEMUA 191 Alarm Management Process
Source:
EEMUA 191
Suggestions for
improvement
Change
management
Implementation
Reconciliation with standards
Data collection
Analysis
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15. Measure Catalog for the Alarm Management
Alarm structure
Definition of an alarm concept
Alarm database with change management
Alarm priorities
Definition operation modes
Process scenarios
Failure scenarios
Definition of alarms group
Definition of alarm suppression logic
for alarm groups
for operation modes
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16. System 800xA Alarm Management Analysis functions according to EEMUA 191
Allocation of alarm priorities
Ranking list: Alarm list sorted by the frequency of the alarms
Average number of alarms divided by the maximum number of alarms per hour (EEMUA 191)
Alarm management reports
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17. System 800xA Alarm Management Key Performance Indicator (KPI)
KPI´s are used as a basis for continuous improvements
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18. System 800xA Alarm Management Alarm Hiding
Alarm Bands
Alarm List
Hidden Alarm List
Alarm Hiding
Definition of alarm suppression logic
for alarm groups
for operation modes
Hidden alarms are displayed exclusively in the Hidden Alarm List
Reduction of the active alarms (which need an operator action)
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19. System 800xA Alarm Management Alarm Shelving
Shelve Alarm
The “Shelving” function defers alarms temporarily e.g. due to maintenance activities
A “shelved” alarm will be active again after an adjustable time period
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20. Role based alarm handling
Many alarms are only dedicated to a special group of operators
The runtime of a device has accumulated up to a configured limit
A switchover alarm to a redundant device (e.g. pump)
A hard disk allocation is near to the capacity limit
These alarms should be sent directly to their target group (e.g. maintenance group) and should not burden the process operators
In System 800xA each target group can get optimal alarm list extracts by extended alarm filtering possibilities
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21. Alarm Database Continuous improvement of the alarm system
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22. Summary
Highly automated power plants may have the problem, that the operator looses the process overview (98 % routine + 2 % stress during failures).
System 800xA
provides all functionality to implement the requirements of EEMUA 191
provides with a new process display functionality and alarm management functions high efficient means to the operator for an optimum control of a power plant and an early detection of upcoming problems.
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